For 3-phase induction motors VF-S11. 3-phase 500V class phase 600V class 0.75

Transcription

1 Industrial Inverter For 3-phase induction motors Instruction Manual TOSVERT TM 1-phase 240V class phase 240V class phase 500V class phase 600V class 0.75 VF-S11 2.2kW 15kW 15kW 15kW NOTICE 1.Make sure that this instruction manual is delivered to the end user of the inverter unit. 2.Read this manual before installing or operating the inverter unit, and store it in a safe place for reference. E Safety precautions Introduction Contents Read first Connection Operations Basic VF-S11 operations Basic parameters Extended parameters Applied operation Monitoring the operation status Measures to satisfy the standards Peripheral devices Table of parameters and data Specifications Before making a service call Inspection and maintenance Warranty Disposal of the inverter 2004 Ver. 108/109 I II

2 I. Safety precautions I The items described in these instructions and on the inverter itself are very important so that you can use the inverter safely, prevent injury to yourself and other people around you as well as to prevent damage to property in the area. Thoroughly familiarize yourself with the symbols and indications shown below and then continue to read the manual. Make sure that you observe all warnings given. Explanation of markings Marking Danger 1 Meaning of marking Indicates that errors in operation may lead to death or serious injury. Indicates that errors in operation may lead to injury (*1) to people or that these errors may Warning cause damage to physical property. (*2) (*1) Such things as injury, burns or shock that will not require hospitalization or long periods of outpatient treatment. (*2) Physical property damage refers to wide-ranging damage to assets and materials. Meanings of symbols Marking Meaning of marking Indicates prohibition (Don't do it). What is prohibited will be described in or near the symbol in either text or picture form. Indicates something mandatory (must be done). What is mandatory will be described in or near the symbol in either text or picture form. Indicates danger. What is dangerous will be described in or near the symbol in either text or picture form. Indicates warning. What the warning should be applied to will be described in or near the symbol in either text or picture form. Limits in purpose This inverter is used for controlling speeds of three-phase induction motors in general industrial use. Safety precautions The inverter cannot be used in any device that would present danger to the human body or from which malfunction or error in operation would present a direct threat to human life (nuclear power control device, aviation and space flight control device, traffic device, life support or operation system, safety device, etc.). If the inverter is to be used for any special purpose, first get in touch with the supplier. This product was manufactured under the strictest quality controls but if it is to be used in critical equipment, for example, equipment in which errors in malfunctioning signal output system would cause a major accident, safety devices must be installed on the equipment. Do not use the inverter for loads other than those of properly applied three-phase induction motors in general industrial use. (Use in other than properly applied three-phase induction motors may cause an accident.)

3 I General Operation Danger Never disassemble, modify or repair. This can result in electric shock, fire and injury. For repairs, call your sales distributor. E See item 2. Disassembly prohibited Prohibited Mandatory Prohibited contact Prohibited Never remove the front cover when power is on or open door if enclosed in a cabinet. The unit contains many high voltage parts and contact with them will result in electric shock. Don't stick your fingers into openings such as cable wiring hole and cooling fan covers. This can result in electric shock or other injury. Don't place or insert any kind of object into the inverter (electrical wire cuttings, rods, wires etc.). This can result in electric shock or fire. Do not allow water or any other fluid to come in contact with the inverter. This can result in electric shock or fire. Turn power on only after attaching the front cover or closing door if enclosed in a cabinet. If power is turned on without the front cover attached or closing door if enclosed in a cabinet, this can result in electric shock or other injury. If the inverter begins to emit smoke or an unusual odor, or unusual sounds, immediately turn power off. If the equipment is continued in operation in such a state, the result may be fire. Call your local sales agency for repairs. Always turn power off if the inverter is not used for long periods of time since there is a possibility of malfunction caused by leaks, dust and other material. If power is left on with the inverter in that state, it may result in fire. Warning Do not touch heat radiating fins or discharge resistors. These device are hot, and you'll get burned if you touch them. Avoid operation in any location where there is direct spraying of the following solvents or other chemicals. The plastic parts may be damaged to a certain degree depending on their shape, and there is a possibility of the plastic covers coming off. If the chemical or solvent is anything other than those shown below, please contact us in advance. (Table 1) Examples of applicable chemicals and solvents Acetic acid (density of 10% or less) Hydrochloric acid (density of 10% or less) Sulfuric acid (density of 10% or less) Sodium chloride Hexane Triethylene glycol (Table 2) Examples of unapplicable chemicals and solvents Acetone Benzene Chloroform Ethylene chloride Ethyl acetate Glycerin Tetrachloroethylene Trichloroethylene Xylene See item

4 Transportation & installation Prohibited Mandatory Danger Do not install or operate the inverter if it is damaged or any component is missing. This can result in electric shock or fire. Please consult your local sales agency for repairs. Call your local sales agency for repairs. Do not place any inflammable objects nearby. If a flame is emitted due to malfunction, it may result in a fire. Do not install in any location where the inverter could come into contact with water or other fluids. This can result in electric shock or fire. Must be used in the environmental conditions prescribed in the instruction manual. Use under any other conditions may result in malfunction. Mount the inverter on a metal plate. The rear panel gets very hot. Do not install in an inflammable object, this can result in fire. Do not operate with the front panel cover removed. This can result in electric shock. Failure to do so can lead to risk of electric shock and can result in death or serious injury. An emergency stop device must be installed that fits with system specifications (e.g. shut off input power then engage mechanical brake). Operation cannot be stopped immediately by the inverter alone, thus risking an accident or injury. All options used must be those specified by Toshiba. The use of any other option may result in an accident. E See item I Prohibited Mandatory Wiring Prohibited Warning When transporting or carrying, do not hold by the front panel covers. The covers may come off and the unit will drop out resulting in injury. Do not install in any area where the unit would be subject to large amounts of vibration. That could result in the unit falling, resulting in injury. The main unit must be installed on a base that can bear the unit's weight. If the unit is installed on a base that cannot withstand that weight, the unit may fall resulting in injury. If braking is necessary (to hold motor shaft), install a mechanical brake. The brake on the inverter will not function as a mechanical hold, and if used for that purpose, injury may result. Danger Do not connect input power to the output (motor side) terminals (U/T1,V/T2,W/T3). That will destroy the inverter and may result in fire. Do not connect resistors to the DC terminals (across PA-PC or PO-PC). That may cause a fire. Connect a resistor in accordance with Within ten minutes after turning off input power, do not touch wires of devices (MCCB) connected to the input side of the inverter. That could result in electric shock. See item See item

5 I Danger See item Mandatory Be Grounded Electrical installation work must be done by a qualified expert. Connection of input power by someone who does not have that expert knowledge may result in fire or electric shock. Connect output terminals (motor side) correctly. If the phase sequence is incorrect, the motor will operate in reverse and that may result in injury. Wiring must be done after installation. If wiring is done prior to installation that may result in injury or electric shock The following steps must be performed before wiring. (1) Turn off all input power. (2) Wait at least ten minutes and check to make sure that the charge lamp is no longer lit. (3) Use a tester that can measure DC voltage (800VDC or more), and check to make sure that the voltage to the DC main circuits (across PA-PC) is 45V or less. If these steps are not properly performed, the wiring will cause electric shock. Tighten the screws on the terminal board to specified torque. If the screws are not tightened to the specified torque, it may lead to fire. Check to make sure that the input power voltage is +10%, -15% of the rated power voltage written on the rating label (±10% when the load is 100% in continuous operation). If the input power voltage is not +10%, -15% of the rated power voltage (±10% when the load is 100% in continuous operation) this may result in fire. Ground must be connected securely. If the ground is not securely connected, it could lead to electric shock or fire when a malfunction or current leak occurs Prohibited Operations Warning Do not attach equipment (such as noise filters or surge absorbers) that have built-in capacitors to the output (motor side) terminals. That could result in a fire. See item 2.1 Prohibited Mandatory Danger Do not touch inverter terminals when electrical power is going to the inverter even if the motor is stopped. Touching the inverter terminals while power is connected to it may result in electric shock. Do not touch switches when the hands are wet and do not try to clean the inverter with a damp cloth. Such practices may result in electric shock. Do not go near the motor in alarm-stop status when the retry function is selected. The motor may suddenly restart and that could result in injury. Take measures for safety, e.g. attaching a cover to the motor, against accidents when the motor unexpectedly restarts. Turn input power on after attaching the front cover. When installed inside a cabinet and using with the front cover removed, always close the cabinet doors first and then turn power on. If the power is turned on with the front cover or the cabinet doors open, it may result in electric shock. Make sure that operation signals are off before resetting the inverter after malfunction. If the inverter is reset before turning off the operating signal, the motor may restart suddenly causing injury. See item

6 Prohibited Warning Observe all permissible operating ranges of motors and mechanical equipment. (Refer to the motor's instruction manual.) Not observing these ranges may result in injury. See item 3. I When sequence for restart after a momentary failure is selected (inverter) Mandatory Warning Stand clear of motors and mechanical equipment. If the motor stops due to a momentary power failure, the equipment will start suddenly after power recovers. This could result in unexpected injury. Attach warnings about sudden restart after a momentary power failure on inverters, motors and equipment for prevention of accidents in advance. See item When retry function is selected (inverter) Mandatory Warning Stand clear of motors and equipment. If the motor and equipment stop when the alarm is given, selection of the retry function will restart them suddenly after the specified time has elapsed. This could result in unexpected injury. Attach warnings about sudden restart in retry function on inverters, motors and equipment for prevention of accidents in advance. See item Maintenance and inspection Prohibited Mandatory Danger Do not replace parts. This could be a cause of electric shock, fire and bodily injury. To replace parts, call the local sales agency. The equipment must be inspected every day. If the equipment is not inspected and maintained, errors and malfunctions may not be discovered and that could result in accidents. Before inspection, perform the following steps. (1) Turn off all input power to the inverter. (2) Wait at least ten minutes and check to make sure that the charge lamp is no longer lit. (3) Use a tester that can measure DC voltages (800VDC or more), and check to make sure that the voltage to the DC main circuits (across PA-PC) is 45V or less. If inspection is performed without performing these steps first, it could lead to electric shock. See item

7 I Disposal Mandatory Warning If you throw away the inverter, have it done by a specialist in industry waste disposal(*). If you throw away the inverter by yourself, this can result in explosion of capacitor or produce noxious gases, resulting in injury. (*) Persons who specialize in the processing of waste and known as "industrial waste product collectors and transporters" or "industrial waste disposal persons. "If the collection, transport and disposal of industrial waste is done by someone who is not licensed for that job, it is a punishable violation of the law. (Laws in regard to cleaning and processing of waste materials) E See item 16. Attach warning labels Shown here are examples of warning labels to prevent, in advance, accidents in relation to inverters, motors and other equipment. Be sure to affix the caution label where it is easily visible when selecting the auto-restart function (6.13.1) or the retry function (6.13.3). If the inverter has been programmed for restart sequence of momentary power failure, place warning labels in a place where they can be easily seen and read. (Example of warning label) Warning (Functions programmed for restart) Do not go near motors and equipment. Motors and equipment that have stopped temporarily after momentary power failure will restart suddenly after recovery. If the retry function has been selected, place warning labels in a location where they can be easily seen and read. (Example of warning label) Warning (Functions programmed for retry) Do not go near motors and equipment. Motors and equipment that have stopped temporarily after an alarm will restart suddenly after the specified time has elapsed. 6

8 II. Introduction Thank you for your purchase of the Toshiba "TOSVERT VF-S11 industrial inverter. This is the Ver.108 / Ver.109 CPU version inverter. Please be informed that CPU version will be frequently upgraded. II Features 1. Built-in noise filter 1) All models in both the 240V and 500V series have a noise filter inside. (Except 600V series) 2) Can be compliant with European CE marking standard 3) Reduces space requirements and cuts down on time and labor needed in wiring. 2. Simple operation 1) Automatic functions (torque boost acceleration/deceleration time, function programming) Just by wiring the motor to the power supply allows instant operation without the need to program parameters. 2) The potentiometer dial and the RUN/STOP button allow easy operation. 3. Superior basic performance 1) 200% or more starting torque 2) Smooth operation : Reduced rotation ripple through the use of Toshiba's unique waveform formation. 3) Built-in current surge suppression circuit : Can be safely connected even if power load is low. 4) Maximum 500Hz high frequency output : Optimum for use with high speed motors such as those in lumber machinery and milling machines. 5) Maximum carrier frequency : 16kHz quiet operation Toshiba's unique PWM control reduces noise at low carrier. 4. Globally compatible 1) Compatible with 240V, 500V and 600V power supplies 2) Conforms to CE marking and with UL, CSA. 3) Sink/source switching of control input/output. 5. Options allow use with a wide variety of applications Internal communications devices (RS485, Modbus RTU, DeviceNET, LonWorks etc.) Extension panel/parameter writer DIN rail kit EMC noise reduction filter (Foot mount and side mount installation) Other options are common to all models 6. Extended power range Wide range of powers up to 15kW for this class of inverter. Totally enclosed box type. 7

9 Contents I Safety precautions...1 II Introduction Read first...a Check product purchase...a Contents of the product...a Names and functions...a Notes on the application...a Connection...B Cautions on wiring...b Standard connections...b Description of terminals...b-5 3. Operations...C Simplified operation of the VF-S11...C How to operate the VF-S11...C-6 4. Basic VF-S11 operations...d Flow of status monitor mode...d How to set parameters...d-3 5. Basic parameters...e Setting acceleration/deceleration time...e Increasing starting torque...e Specifying an operation mode, using parameters...e Selection of operation mode...e Meter setting and adjustment...e Standard default setting...e Forward/reverse run selection (Operation panel operation)...e Maximum frequency...e Upper limit and lower limit frequencies...e Base frequency...e Selecting control mode...e Manual torque boost - increasing torque boost at low speeds...e Setting the electronic thermal...e Preset-speed operation (speeds in 15 steps)...e Extended parameters...f Input/output parameters...f-1 i

10 6.2 Input signal selection...f Terminal function selection...f Basic parameters 2...F Frequency priority selection...f Operation frequency...f DC braking...f Auto-stop in case of lower-limit frequency continuous operation...f Jog run mode...f Jump frequency-jumping resonant frequencies...f Preset-speed operation frequencies...f PWM carrier frequency...f Trip-less intensification...f Drooping control...f Braking setting functions...f Conducting PID control...f Setting motor constants...f Acceleration/deceleration Patterns 2 and 3...F Protection functions...f Adjustment parameters...f Operation panel parameter...f Communication function (Common serial)...f Parameters for options...f Permanent magnetic motors...f Applied operation...g Setting the operation frequency...g Setting the operation mode...g-5 8. Monitoring the operation status...h Status monitor mode...h Display of trip information...h-5 9. Measures to satisfy the standards...i How to cope with the CE directive...i Compliance with UL Standard and CSA Standard...I Peripheral devices...j Selection of wiring materials and devices...j Installation of a magnetic contactor...j Installation of an overload relay...j Optional external devices...j Table of parameters and data...k User parameters...k-1 ii

11 11.2 Basic parameters...k Extended parameters...k Specifications...L Models and their standard specifications...l Outside dimensions and mass...l Before making a service call - Trip information and remedies...m Trip causes/warnings and remedies...m Restoring the inverter from a trip...m If the motor does not run while no trip message is displayed...m How to determine the causes of other problems...m Inspection and maintenance...n Regular inspection...n Periodical inspection...n Making a call for servicing...n Keeping the inverter in storage...n Warranty...O Disposal of the inverter...p-1 iii

12 1. Read first 1.1 Check product purchase Mandatory Before using the product you have purchased, check to make sure that it is exactly what you ordered. Warning Use an inverter that conforms to the specifications of power supply and three-phase induction motor being used. If the inverter being used does not conform to those specifications, not only will the three-phase induction motor not rotate correctly, it may also cause serious accidents through overheating and fire. 1 Rating label Inverter main unit Series name Power supply Motor capacity VF-S11 1PH-200/240V-0.75kW/1HP Warning label Carton box Name plate Type indication label Instruction manual This manual Name plate Inverter Type Inverter rated output capacity Power supply Related input current Related output current Warning label EMC plate A-1

13 1.2 Contents of the product Explanation of the name plate label. 1 Type Form V F S 11 S P L E - W N - A 2 2 Model name TOSVERT VF-S11series Number of power phases S: single-phase None: three-phase Input (AC) voltage 2 : 200V to 240V 4 : 380V to 500V 6 : 525V to 600V Applicable motor capacity 002 : 0.2kW 004 : 0.4kW 005 : 0.55kW 007 : 0.75kW 015 : 1.5kW 022 : 2.2kW 037 : 3.7kW 055 : 5.5kW 075 : 7.5kW 110 : 11kW 150 : 15kW Additional functions I None: No filter inside M: Built-in basic filter L: Built-in high-attenuation EMI filter Operation panel Default interface logic* WN, AN : Negative WP : Positive Additional function II None: Standard product E: Enclosed type U: Open type R: With a built-in RS-485 circuit board Special specification code A : is the number P: Provided * This code represents the factory default logic setting. You can switch from one input/output logic to the other using slide switch SW1. (See 2.3.2) Warning: Always shut power off first then check the ratings label of inverter held in a cabinet. A-2

14 1.3 Names and functions Outside view RUN lamp Lights when an ON command is issued but no frequency signal is sent out. It blinks when operation is started. Percent (%) lamp Lights when a numeric value is displayed in %. 1 PRG lamp Lights when the inverter is in parameter setting mode. Blinks when the inverter is placed in AUH Gr. U mode. MON lamp Lights when the inverter is in monitor mode. Blinks when the inverter is placed in trip record display mode. Up key Hertz (Hz) lamp Lights when a numeric value is displayed in Hz. Built-in potentiometer lamp Operation frequency can be changed when the built-in potentiometer lamp is lit. MODE key Displays operation frequency, parameters, and error causes. Up/Down key lamp Pressing up or down key when this lamp is lighted allows the setting of operation frequency. Enter key Built-in potentiometer Down key STOP key RUN key lamp Lights when the RUN key is enabled. RUN key Pressing this key while the RUN key lamp is lit starts operation. [Front panel 1] Every pressing of this key while the RUN key lamp is lit will cause a slowdown to a stop. A-3

15 1 Charge lamp Indicates that high voltage is still present within the inverter. Do not open the terminal board cover while this is lit. Front panel The front panel of the inverter or terminal board To avoid touching the terminal board by mistake, be sure to close the front panel before starting operation. Unlock position mark The front panel is unlocked when the dot on the locking screw is on this (upper) side. Front panel locking screw The inverter came with this screw in the locked position. So from this position, turn the screw 90 counterclockwise to unlock the front panel, or turn it 90 clockwise to lock the front panel. The screw does not turn 360. To avoid damage to the screw, do not use excessive force when turning it. Lock position mark The front panel is locked when the dot on the locking screw is on this (lower) side. Control cable port Communication connector hole Top warning label Note1) Cooling fin Main circuit cable port Ventilation slit [Bottom] Name plate [Right side] Note 1) Remove this seal when installing the inverter side by side with other inverters where the ambient temperature will rise above 40 C. A-4

16 Example of the label 40 C 50mm Power circuit and control circuit terminal boards In case of the lug connector, cover the lug connector with insulated tube, or use the insulated lug connector. Note 1: EMC plate is supplied as standard. 1) Power circuit terminal board In case of the lug connector, cover the lug connector with insulated tube, or use the insulated lug connector. Screw size tightening torque M3.5 screw 0.9Nm 7.1lb in M4 screw 1.3Nm 10.7lb in M5 screw 2.5Nm 22.3lb in M6 screw 4.5Nm 40.1lb in VFS PM R/L1 S/L2 T/L3 M3.5 screw Shorting-bar PO PA/+ PB PC/ U/T1 V/T2 W/T3 Screw hole for EMC plate Note 1 Grounding terminal (M5 screw) A-5

17 VFS PM R/L1 S/L2 T/L3 M3.5 screw (2015 only) M4 screw (2022, 2037) 1 Shorting-bar PO PA/+ PB PC/ U/T1 V/T2 W/T3 Screw hole for EMC plate Note 1 Grounding terminal (M5 screw) VFS11S PL Grounding capacitor disconnecting switch (See page A-9) R/L1 S/L2 M3.5 screw Shorting-bar PO PA/+ PB PC/ U/T1 V/T2 W/T3 Screw hole for EMC plate Note 1 Grounding terminal (M5 screw) A-6

18 VFS11S-2015, 2022PL Grounding capacitor disconnecting switch (See page A-9) R/L1 S/L2 M4 screw 1 Shorting-bar PO PA/+ PB PC/ U/T1 V/T2 W/T3 Screw hole for EMC plate Note 1 Grounding terminal (M5 screw) VFS PL, P Grounding capacitor disconnecting switch (See page A-9) R/L1 S/L2 T/L3 M4 screw Shorting-bar PO PA/+ PB PC/ U/T1 V/T2 W/T3 Screw hole for EMC plate Note 1 Grounding terminal (M5 screw) A-7

19 VFS , 2075PM -4055, 4075PL, 6055, 6075P 1 Grounding capacitor disconnecting tap M4 screw (See page A-9) (4055, 4075 only) M5 screw R/L1 S/L2 T/L3 PO PA/+ PB PC/ U/T1 V/T2 W/T3 Shorting-bar Screw hole for EMC plate Note 1 Grounding terminal (M5 screw) VFS , 2150PM -4110, 4150PL, 6110, 6150P Grounding capacitor disconnecting tap M4 screw (See page A-9) (4110, 4150 only) M6 screw R/L1 S/L2 T/L3 PO PA/+ PB PC/ U/T1 V/T2 W/T3 Shorting-bar Screw hole for EMC plate Note 1 Grounding terminal (M5 screw) A-8

20 2) Grounding capacitor disconnecting switch and taps Mandatory Warning The grounding capacitor disconnecting tap is provided with a protection cover. To avoid shock hazards, always attach the cover after connecting or disconnecting the capacitor to or from the tap. Every single-phase 240V/three-phase 500V model has a built-in high-attenuation noise filter, which is grounded through a capacitor. If you want to disconnect the capacitor from the grounding line to reduce the amount of leakage current, you can do so easily using the switch or tap. Keep in mind, however, that disconnecting the capacitor from the grounding line causes the inverter to become non-compliant with the EMC directive. Also note that the inverter must always be turned off before the capacitor is disconnected or reconnected. Note) In case of three phase 500V-4.0kW model, if you disconnect the capacitor from ground, set the parameter of carrier frequency f300 to 4kHz or less with motor cable length 30m or less kW or less : Switch To connect the capacitor to ground, push this switch. (Factory default position) To disconnect the capacitor from ground, pull up this switch. 5.5kW or more : Tap To disconnect the capacitor from ground, connect the lug terminal to this tap. To connect the capacitor to ground, connect the lug terminal to this tap. (Factory default setting) A-9

21 3) Control circuit terminal board The control circuit terminal board is common to all equipment. 1 SW1 SOURCE PLC SINK P24 OUT NO FM CC FLA FLB FLC RY RC PP VIA VIB CC FM VIA V V I I PLC S1 S2 S3 M3 screw (0.5N m) F R RES CC Optional connector (RJ45) Wire size Solid wire: (mm 2 ) Stranded wire: (mm 2 ) (AWG 22 16) Sheath strip length: 6 (mm) Factory default settings of slide switches SW1: SINK (Negative) side (WN, AN type) SOURCE (Positive) side (WP type) FM: V side VIA: V side Screwdriver: Small-sized flat-blade screwdriver (Blade thickness: 0.4 mm or less, blade width: 2.2 mm or less) See for details on all terminal functions. A-10

22 1.3.3 How to open the front (terminal board) cover To wire the terminal board, remove the front lower cover in line with the steps given below. (1) (2) 1 Turn the locking screw on the right side of the front panel 90 counterclockwise to align the dot on the screw with the unlock position mark (upper side). To avoid damage to the screw, do not apply excessive force to turn the screw more than 90 degrees. Pull the front panel toward you and swing it open to the left. (3) (4) Terminal board cover Wiring port cover Remove the terminal board cover by pulling it up toward you. Remove the wiring port cover by pulling it down, pass cables through the wiring port, and connect the cables to the terminal board. A-11

23 1.4 Notes on the application Motors 1 When the VF-S11 and the motor are used in conjunction, pay attention to the following items. Warning Use an inverter that conforms to the specifications of power supply and three-phase induction motor being used. If the inverter being used does not conform to those specifications, not only will the threephase induction motor not rotate correctly, but it may cause serious accidents through overheating and Mandatory fire. Comparisons with commercial power operation. The VF-S11 Inverter employs the sinusoidal PWM system. However, the output voltage and output current are not perfect sine waves, they have a distorted wave that is close to sinusoidal waveform. This is why compared to operation with a commercial power there will be a slight increase in motor temperature, noise and vibration. Operation in the low-speed area When running continuously at low speed in conjunction with a general purpose motor, there may be a decline in that motor's cooling effect. If this happens, operate with the output decreased from rated load. To carry out low-speed operation continuously at the rated torque, we recommend to use a inverter rated motor or a forced cooled motor designed for use with an inverter. When operating in conjunction with a inverter rated motor, you must change the inverter's motor overload protection level to VF motor use ( ). Adjusting the overload protection level The VF-S11 Inverter protects against overloads with its overload detection circuits (electronic thermal). The electronic thermal's reference current is set to the inverter's rated current, so it must be adjusted in line with the rated current of the general purpose motor being used in combination. High speed operation at and above 60Hz Operating at frequencies greater than 60Hz will increase noise and vibration. There is also a possibility this will exceed the motor's mechanical strength limits and the bearing limits so you should inquire to the motor's manufacturer about such operation. Method of lubricating load mechanisms Operating an oil-lubricated reduction gear and gear motor in the low-speed areas will worsen the lubricating effect. Check with the manufacturer of the reduction gear to find out about operable gearing area. A-12

24 Low loads and low inertia loads The motor may demonstrate instability such as abnormal vibrations or overcurrent trips at light loads of 50 % or under of the load percentage, or when the load's inertia moment is extremely small. If that happens reduce the carrier frequency. Occurrence of instability Unstable phenomena may occur with the load and motor combinations shown below. Combined with a motor that exceeds applicable motor ratings recommended for the inverter Combined with special motors For 600V class or 500V class with long cable To deal with the above lower the settings of inverter carrier frequency. Combined with couplings between load devices and motors with high backlash When using the inverter in the above combination, use the S-pattern acceleration/deceleration function, or when vector control is selected, adjust the speed control response/stability factor or switch to V/f control mode. Combined with loads that have sharp fluctuations in rotation such as piston movements In this case, adjust the response time (inertial moment setting) during vector control or switch to V/f control. 1 Braking a motor when cutting off power supply A motor with its power cut off goes into free-run, and does not stop immediately. To stop the motor quickly as soon as the power is cut off install an auxiliary brake. There are different kinds of brake devices, both electrical and mechanical. Select the brake that is best for the system. Load that produces regenerative torque When combined with a load that produces regenerative torque, the overvoltage or overcurrent protection function may be activated to trip the inverter. For this kind of situation, you must install a dynamic braking resistor that complies with the load conditions, or increase deceleration time. A-13

25 Braking motor When using a braking motor, if the braking circuit is directly connected to the inverters's output terminals, the brake cannot be released because of the lowered starting voltage. Therefore, when using a braking motor, connect the braking circuit to the inverter's power supply side, as shown in the figure below. Usually, braking motors produce larger noise in low speed ranges. 1 Note: In the case of the circuit shown on the below, assign the function of detecting low-speed signals to the RY and RC terminals. Make sure the parameter f130 is set to 4 (factory default setting). MC2 Non-excitation activation type brake B Power supply MC1 F CC RY RY RC IM MC2 Run/stop Measures to protect motors against surge voltages In a system in which a 500V-class inverter is used to control the operation of a motor, very high surge voltages may be produced. When applied to the motor coils repeatedly for a long time, may cause deterioration of their insulation, depending on the cable length, cable routing and types of cables used. Here are some examples of measures against surge voltages. (1) Lower the inverter s carrier frequency. (2) Set the parameter f316 (Carrier frequency control mode selection) to 2 or 3. (3) Use a motor with high insulation strength. (4) Insert an AC reactor or a surge voltage suppression filter between the inverter and the motor Inverters Protecting inverters from overcurrent The inverter has an overcurrent protection function. The programmed current level is set to the inverter's maximum applicable motor. If the motor used has a small capacity, the overcurrent level and the electronic thermal protection must be readjusted. If adjustment is necessary, see 5-13, and make adjustments as directed. Inverter capacity Do not use a small-capacity (kva) inverter to control the operation of a large-capacity motor (two-class or more larger motor), no matter how light the load is. Current ripple will raise the output peak current making it easier to set off the overcurrent trip. A-14

26 Power factor correction capacitor Power factor correction capacitors cannot be installed on the output side of the inverter. When a motor is run that has a power factor correction capacitor attached to it, remove the capacitors. This can cause inverter malfunction trips and capacitor destruction. U/T1 Inverter V/T2 W/T3 IM 1 Remove the power factor correction capacitor and surge absorber Power factor correction capacitor Operating at other than rated voltage Connections to voltages other than the rated voltage described in the rating label cannot be made. If a connection must be made to a power supply other than one with rated voltage, use a transformer to raise or lower the voltage to the rated voltage. Circuit breaking when two or more inverters are used on the same power line. MCCB1 MCCB2 MCCB3 (circuit breaking fuse) INV1 INV2 MCCBn+1 INVn Breaking of selected inverter There is no fuse in the inverter's main circuit. Thus, as the diagram above shows, when more than one inverter is used on the same power line, you must select interrupting characteristics so that only the MCCB2 will trip and the MCCB1 will not trip when a short occurs in the inverter (INV1). When you cannot select the proper characteristics install a circuit interrupting fuse between the MCCB2 and the INV1. If power supply distortion is not negligible If the power supply distortion is not negligible because the inverter shares a power distribution line with other systems causing distorted waves, such as systems with thyristors or large-capacity inverters, install an input reactor to improve the input power factor, to reduce higher harmonics, or to suppress external surges. A-15

27 Disposal If an inverter is no longer usable, dispose of it as industrial waste What to do about the leak current 1 Warning Current may leak through the inverter's input/output wires because of insufficient electrostatic capacity on the motor with bad effects on peripheral equipment. The leakage current s value is affected by the carrier frequency and the length of the input/output wires. Test and adopt the following remedies against leak current. (1) Effects of leak current across ground Leakage current may flow not just through the inverter system but also through ground wires to other systems. Leakage current will cause earth leakage breakers, leakage current relays, ground relays, fire alarms and sensors to operate improperly, and it will cause superimposed noise on the CRT screen or display of incorrect current detection with the CT. Power supply ELCB Inverter M ELCB Inverter M Leakage current path across ground Remedies: 1.If there is no radio-frequency interference or similar problem, detach the built-in noise filter capacitor, using the grounding capacitor disconnecting switch or tap. (See ) 2.Reduce PWM carrier frequency. The setting of PWM carrier frequency is done with the parameter. Although the electromagnetic noise level is reduced, the motor acoustic noise is increased. 3. Use high frequency remedial products for earth leakage breakers. A-16

28 (2) Affects of leakage current across lines Thermal relays Power supply Inverter CT M Leakage current path across wires A 1 (1) Thermal relays The high frequency component of current leaking into electrostatic capacity between inverter output wires will increase the effective current values and make externally connected thermal relays operate improperly. If the wires are more than 50 meters long, it will be easy for the external thermal relay to operate improperly with models having motors of low rated current (several A(ampere) or less), especially the 500V and 600V class low capacity (3.7kW or less) models, because the leak current will increase in proportion to the motor rating. Remedies: 1.Use the electronic thermal built into the inverter. (See 5.13) The setting of the electronic thermal is done using parameter,. 2.Reduce the inverter's PWM carrier frequency. However, that will increase the motor's magnetic noise. The setting of PWM carrier frequency is done with the parameter. (See 6.12) 3.This can be improved by installing 0.1µ~0.5µF V film capacitor to the input/output terminals of each phase in the thermal relay. U/T1 V/T2 IM W/T3 Thermal relays A-17

29 1 (2) CT and ammeter If a CT and ammeter are connected externally to detect inverter output current, the leak current's high frequency component may destroy the ammeter. If the wires are more than 50 meters long, it will be easy for the high frequency component to pass through the externally connected CT and be superimposed on and burn the ammeter with models having motors of low rated current (several A(ampere) or less), especially the 500V and 600V class low capacity (3.7kW or less) models, because the leak current will increase in proportion to the motor's rated current. Remedies: 1.Use a meter output terminal in the inverter control circuit. The load current can be output on the meter output terminal (FM). If the meter is connected, use an ammeter of 1mAdc full scale or a voltmeter of 7.5V-1mA full scale. 0-20mAdc (4-20mAdc) can be also output. (See 5.5) 2.Use the monitor functions built into the inverter. Use the monitor functions on the panel built into the inverter to check current values. (See 8.1.1) Installation Installation environment The VF-S11 Inverter is an electronic control instrument. Take full consideration to installing it in the proper operating environment. Danger Do not place any inflammable substances near the VF-S11 Inverter. If an accident occurs in which flame is emitted, this could lead to fire. Prohibited Operate under the environmental conditions prescribed in the instruction manual. Operations under any other conditions may result in malfunction. Mandatory Warning Do not install the VF-S11 Inverter in any location subject to large amounts of vibration. This could cause the unit to fall, resulting in bodily injury. Prohibited Mandatory Check to make sure that the input power voltage is +10%, -15% of the rated power voltage written on the rating label (±10% when the load is 100% in continuous operation) If the input power voltage is not +10%, -15% of the rated power voltage (±10% when the load is 100% in continuous operation) this may result in fire. A-18

30 Warning Prohibited Avoid operation in any location where there is direct spraying of the following solvents or other chemicals. The plastic parts may be damaged to a certain degree depending on their shape, and there is a possibility of the plastic covers coming off. If the chemical or solvent is anything other than those shown below, please contact us in advance. ((Table 1) Examples of applicable chemicals and solvents Acetic acid (density of 10% or less) Hydrochloric acid (density of 10% or less) Sulfuric acid (density of 10% or less) Sodium chloride Hexane Triethylene glycol (Table 2) Examples of unapplicable chemicals and solvents Acetone Benzene Chloroform Ethylene chloride Ethyl acetate Glycerin Tetrachloroethylene Trichloroethylene Xylene 1 Note: The plastic cover has resistance to deformation by the above applicable solvents. They are not examples for resistance to fire or explosion. Do not install in any location of high temperature, high humidity, moisture condensation and freezing and avoid locations where there is exposure to water and/or where there may be large amounts of dust, metallic fragments and oil mist. Do not install in any location where corrosive gases or grinding fluids are present. Operate in areas where ambient temperature ranges from -10 C to 60 C. Operation over 40 C is allowed when the top label is peeled off. When installing the inverter where the ambient temperature will rise above 50 C, remove the label (seal) from the top and operate it at a current lower than the rated one. 5cm 5cm Measurement position 5cm Measurement position Note: The inverter is a heat-emitting body. Make sure proper space and ventilation is provided when installing in the cabinet. When installing inside a cabinet, we recommend the top seal peeled off although 40 C or less. A-19

31 Do not install in any location that is subject to large amounts of vibration. 1 Note: If the VF-S11 Inverter is installed in a location that is subject to vibration, anti-vibration measures are required. Please consult with Toshiba about these measures. If the VF-S11 Inverter is installed near any of the equipment listed below, provide measures to insure against errors in operation. Resistors Solenoids: Brakes: Magnetic contactors: Fluorescent lights: Resistors: Attach surge suppressor on coil. Attach surge suppressor on coil. Attach surge suppressor on coil. Attach surge suppressor on coil. Place far away from VF-S11 Inverter. How to install Prohibited Mandatory Mandatory Danger Do not install or operate the inverter if it is damaged or any component is missing. This can result in electric shock or fire. Please consult your local sales agency for repairs. Call your local sales agency for repairs. Mount the inverter on a metal plate. The rear panel gets very hot. Do not install in an inflammable object, this can result in fire. Do not operate with the front panel cover removed. This can result in electric shock. An emergency stop device must be installed that fits with system specifications (e.g. shut off input power then engage mechanical brake). Operation cannot be stopped immediately by the inverter alone, thus risking an accident or injury. All options used must be those specified by Toshiba. The use of any other option may result in an accident. Warning The main unit must be installed on a base that can bear the unit's weight. If the unit is installed on a base that cannot withstand that weight, the unit may fall resulting in injury. If braking is necessary (to hold motor shaft), install a mechanical brake. The brake on the inverter will not function as a mechanical hold, and if used for that purpose, injury may result. A-20

32 Install the inverter in a well-ventilated indoor place and mount it on a flat metal plate in portrait orientation. If you are installing more than one inverter, the separation between inverters should be at least 5 centimeters, and they should be arranged in horizontal rows. If the inverters are horizontally arranged with no space between them (side-by-side installation), peel off the ventilation seals on top of the inverter. It is necessary to decrease the current if the inverter is operated at over 50 C. Standard installation 10 cm or more Side-by-side installation 10 cm or more Remove seals on top 1 VFS11 VFS11 VFS11 VFS11 5 cm or more 5 cm or more 10 cm or more 10 cm or more The space shown in the diagram is the minimum allowable space. Because air cooled equipment has cooling fans built in on the top or bottom surfaces, make the space on top and bottom as large as possible to allow for air passage. Note: Do not install in any location where there is high humidity or high temperatures and where there are large amounts of dust, metallic fragments and oil mist. Calorific values of the inverter and the required ventilation About 5% of the rated power of the inverter will be lost as a result of conversion from AC to DC or from DC to AC. In order to suppress the rise in temperature inside the cabinet when this loss becomes heat loss, the interior of the cabinet must be ventilated and cooled. The amount of forcible air-cooling ventilation required and the necessary heat discharge surface quantity when operating in a sealed cabinet according to motor capacity are as follows. Notes 1) The heat loss for the optional external devices (input reactor, DC reactor, radio noise reduction filters, etc.) is not included in the calorific values in the table 2) Case of 100% Load Continuation operation. A-21

33 1 Voltage class Single-phase 240V class Three -Phase 240V class Three-Phase 500V class Three-Phase 600V class Operating motor Calorific Values Amount of forcible air Heat discharge surface capacity Inverter type Carrier Carrier cooling ventilation area required for sealed frequency frequency (kw) 4kHz 12kHz required (m /min) storage cabinet(m ) PL PL VFS11S- 2007PL PL PL PM PM PM PM PM VFS PM PM PM PM PM PM PL PL PL PL VFS PL PL PL PL PL P P P P VFS P P P P Panel designing taking into consideration the effects of noise The inverter generates high frequency noise. When designing the control panel setup, consideration must be given to that noise. Examples of measures are given below. Wire so that the main circuit wires and the control circuit wires are separated. Do not place them in the same conduit, do not run them parallel, and do not bundle them. Provide shielding and twisted wire for control circuit wiring. Separate the input (power) and output (motor) wires of the main circuit. Do not place them in the same conduit, do not run them parallel, and do not bundle them. Ground the inverter ground terminals ( ). Install surge suppressor on any magnetic contactor and relay coils used around the inverter. Install noise filters if necessary. A-22

34 Install EMC plate and use shielded wires. 1 EMC plate Installing more than one unit in a cabinet If you are installing two or more inverters in one cabinet, pay attention to the following. Inverters may be installed side by side with each other with no space left between them. When installing inverters side by side, detach the caution label on the top surface of each inverter and use them where the ambient temperature will not rise above 40 C. When using inverters where the ambient temperature will rise above 40 C, leave a space of 5 cm or more between them and remove the caution label from the top of each inverter, or operate each inverter at a current lower than the rated one. Ensure a space of at least 20 centimeters on the top and bottom of the inverters. Install an air deflecting plate so that the heat rising up from the inverter on the bottom does not affect the inverter on the top. Ventilation fan Inverter Air deflecting plate Inverter A-23